A high-power charging device

Abstract

The utility model relates to electric automobile charging equipment technical field especially relates to a kind of high-power charging device, whole installation is in shell, including annular coil group, busbar distribution board, power module, connecting wire group, control mainboard, cooling fan and output port area.The shell is metal rectangular structure, inside is sequentially provided with busbar layer, power layer and control layer from bottom to top.Annular coil group is installed in bottom left side, for input filter and electromagnetic interference suppression;Busbar distribution board is arranged above it, to realize the multiway distribution of energy;Power module is arranged along middle part, each module is independent DC / DC conversion unit, is connected with output port area by connecting wire group, to realize four-way independent output;Control mainboard is used to monitor each voltage, current and temperature parameter, and adjusts cooling fan to realize dynamic temperature control.The device is designed by modularization partition, and has multiway independent output, high-efficiency heat dissipation and maintenance convenience.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle charging equipment technology, and in particular to a high-power charging device. Background Technology

[0002] Currently, high-power electric vehicle charging devices, as an important component of new energy vehicle infrastructure, are widely used in scenarios such as bus depots, public parking lots, and highway service areas. Existing charging equipment typically adopts a single- or dual-output structure, with power modules centrally arranged in the same power channel. This results in complex internal bus connections, low heat dissipation efficiency, and a susceptibility to overheating or electromagnetic interference between modules under high load conditions. Furthermore, multi-channel charging systems lack independent control and isolation mechanisms between channels, meaning that a failure in one channel often affects the overall system's operational stability.

[0003] On the other hand, traditional high-power charging devices generally suffer from low space utilization and difficult maintenance due to their structural layout. Their internal power conversion units and control units are often stacked, resulting in poor heat dissipation and severe heat accumulation during long-term operation, thus shortening the lifespan of critical components (such as IGBT modules and electrolytic capacitors). Therefore, designing a high-power charging device is essential. Utility Model Content

[0004] The purpose of this invention is to provide a high-power charging device to solve the problems mentioned in the background art.

[0005] To solve the above-mentioned technical problems, this utility model provides the following technical solution: a high-power charging device, comprising a housing, a ring coil assembly, a busbar distribution plate, a power module, a connecting wire assembly, a control main board, a cooling fan, and an output port area; the housing is a metal rectangular structure, with a busbar layer, a power layer, and a control layer arranged sequentially from bottom to top inside; the ring coil assembly is installed at the bottom of the housing for input filtering and electromagnetic interference suppression; the busbar distribution plate is disposed above the ring coil assembly for distributing DC power to each power module; the power module is an independent DC / DC conversion unit, with its input end connected to the busbar distribution plate and its output end connected to the output port area via the connecting wire assembly; the control main board is electrically connected to the power module; the cooling fan is disposed inside the housing for cooling the ring coil assembly and the power module; the output port area includes multiple independent output ports.

[0006] According to the above technical solution, the busbar distribution plate is a multi-layer copper busbar structure and is fixed to the bottom of the outer casing by an insulating bracket.

[0007] According to the above technical solution, the power module adopts a detachable plug-in structure, which facilitates individual maintenance and replacement.

[0008] According to the above technical solution, the connecting wire assembly is composed of multiple strands of copper wire and is covered with a high-temperature resistant silicone rubber insulation layer.

[0009] According to the above technical solution, the control motherboard is equipped with a main control chip, a voltage and current sampling circuit, and a communication interface module.

[0010] According to the above technical solution, the cooling fan is provided with a flow guide grille.

[0011] Compared with existing technologies, the beneficial effects achieved by this utility model are as follows: This utility model, through a layered modular structure comprising a ring coil group, a busbar distribution board, independent power modules, and a control motherboard, creates independent functional areas for input filtering, energy distribution, power conversion, and intelligent control within the device, enabling efficient charging with multiple independent outputs. The combination of a multi-layer copper busbar structure and detachable power modules reduces current unevenness and maintenance complexity. The inclusion of a cooling fan and airflow ducts improves overall heat dissipation efficiency. Furthermore, the electromagnetic lock and temperature monitoring device in the output port area ensure safe control and stable system operation during the charging process. The overall structure is compact, heat dissipation is efficient, and maintenance is convenient, enabling the simultaneous provision of safe and reliable high-power charging services for multiple electric vehicles. Attached Figure Description

[0012] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the overall structure of a high-power charging device proposed in this utility model; Figure 2 This is a schematic diagram of the internal structure of a high-power charging device proposed in this utility model.

[0013] In the diagram: 1. Outer casing, 2. Ring coil group, 3. Busbar distribution board, 4. Power module, 5. Connecting wire group, 6. Control main board, 7. Cooling fan, 8. Output port area. Detailed Implementation

[0014] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0015] Example: Reference Figure 1-2A high-power charging device is installed entirely within a housing 1 and mainly includes a ring coil group 2, a busbar distribution board 3, a power module 4, a connecting wire group 5, a control main board 6, a cooling fan 7, and an output port area 8.

[0016] The outer casing 1 is a rectangular metal structure made of aluminum alloy or stainless steel plate. The top cover is fixed to the casing with screws and can be disassembled for internal maintenance. Ventilation openings and dust filters are provided on the front and rear side walls of the outer casing 1, and a mounting base is provided at the bottom for fixing the overall position of the unit. The interior of the outer casing is divided into three functional areas from bottom to top: a busbar layer, a power layer, and a control layer.

[0017] The toroidal coil group 2 is installed on the bottom left side of the housing 1, and consists of multiple high-frequency iron powder core or iron-silicon-aluminum magnetic core coils. Each coil is fixed to the mounting base plate with bolts. The input end of each coil is connected to an external DC power supply interface, and the output end is connected to the bus distribution board 3. This toroidal coil group 2 is used to filter the input current, store energy, and suppress electromagnetic interference, ensuring the power supply stability of the subsequent power module 4.

[0018] The busbar distribution plate 3 is located above the toroidal coil group 2. It is a flat conductor structure with multiple layers of copper busbars stacked on top of it, and is equipped with fuse protection units and branch terminals. The input end of the busbar distribution plate 3 is connected to the toroidal coil group 2, and the output end extends to the input port of the power module 4, used to distribute high-voltage DC energy to each power channel according to the circuit. The busbar distribution plate 3 is fixed to the bottom plate inside the housing by an insulating bracket and is isolated from the grounding busbar.

[0019] Power modules 4 are arranged horizontally along the middle of the outer casing 1, with a total of four modules, each being an independent DC / DC conversion unit. Power modules 4 integrate a high-frequency transformer, IGBT driver board, filter capacitors, and control interface to convert the bus voltage into a constant voltage, constant current DC output. The input terminal of power module 4 is electrically connected to the bus distribution board via conductive tabs, and the output terminal is connected to the output port area 8 via connecting wire group 5. The modules adopt a detachable plug-in structure for easy independent maintenance and replacement.

[0020] The connecting wire assembly 5 consists of several high-temperature resistant flexible cables, internally using multi-strand copper wires and covered with a silicone rubber insulation layer. The upper end of the connecting wire assembly 5 connects to the output terminal of the power module 4, and the lower end extends to the output port area 8. Some wire branches also connect to the control motherboard 6 for transmitting detection signals and communication control signals. The wire arrangement adopts a layered binding structure and is fixed with wire clips and guide grooves to prevent vibration and wear.

[0021] The control motherboard 6 is mounted on the right vertical surface of the housing 1 and is a multi-layer printed circuit board structure. The control motherboard houses the main control chip, voltage and current sampling circuits, a CAN communication module, and a fault detection unit. The control motherboard 6 is electrically connected to each power module 4 via wire group 5, enabling voltage and current sampling, current sharing control, and temperature monitoring for four independent charging channels. Remote control and data upload are achieved between the motherboard and an external monitoring system via a CAN bus communication interface.

[0022] The cooling fan 7 is located at the lower right corner of the outer casing 1, employing an axial flow fan structure with airflow running from left to right throughout the entire interior. A guide grille is installed at the fan outlet, forming a stable airflow path. Cool air flows along the bottom of the power modules and the surface of the ring coil assembly, carrying away the heat generated during operation. The control motherboard 6 has a built-in temperature sensor that automatically adjusts the fan speed based on the temperature rise of each module, achieving dynamic temperature control.

[0023] The output port area 8 is located at the bottom right side of the outer casing 1. It has a multi-interface structure and includes four independent output connection ports. Each output port is equipped with an electromagnetic lock and a temperature sensor, corresponding to a power module 4. When a vehicle access signal is detected, the control motherboard 6 automatically allocates the corresponding power module to start charging; after charging is completed, the output port automatically disconnects, achieving four independent outputs and safety isolation.

[0024] In this embodiment, the components within the outer casing 1 form a layered structure with horizontal partitions. The lower layer is the energy input and filtering area, the middle layer is the power conversion area, and the upper layer and right side are the control and heat dissipation areas. This modular arrangement not only improves the overall space utilization and heat dissipation efficiency but also facilitates future maintenance and expansion.

[0025] During operation, the external high-voltage DC power supply is filtered by the loop coil group 2 and then enters the bus distribution board 3, which distributes it to four power modules 4. Each power module independently outputs to its corresponding output port 8, enabling simultaneous charging of four electric vehicles. The control motherboard 6 monitors the voltage, current, and temperature parameters of each channel in real time and regulates the internal airflow through the cooling fan 7 to ensure long-term stable operation of the system.

[0026] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0027] Finally, it should be noted that the above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A high-power charging device, characterized in that, It includes an outer casing (1), a ring coil assembly (2), a busbar distribution board (3), a power module (4), a connecting wire assembly (5), a control main board (6), a cooling fan (7), and an output port area (8). The outer shell (1) is a metal rectangular structure, and the interior is provided with a bus layer, a power layer and a control layer from bottom to top. The ring coil group (2) is installed at the bottom of the housing and is used for input filtering and electromagnetic interference suppression; the bus distribution plate (3) is set above the ring coil group (2) and is used to distribute DC power to each power module (4). The power module (4) is an independent DC / DC converter unit. Its input end is connected to the bus distribution board (3), and its output end is connected to the output port area (8) via the connecting wire group (5). The control motherboard (6) is electrically connected to the power module (4); The cooling fan (7) is located inside the housing and is used to cool the ring coil assembly (2) and the power module (4). The output port area (8) includes multiple independent output ports.

2. The high-power charging device according to claim 1, characterized in that, The busbar distribution plate (3) is a multi-layer copper busbar structure and is fixed to the bottom of the outer casing (1) by an insulating bracket.

3. The high-power charging device according to claim 1, characterized in that, The power module (4) adopts a detachable plug-in structure, which facilitates individual maintenance and replacement.

4. A high-power charging device according to claim 1, characterized in that, The connecting wire group (5) is composed of multiple strands of copper wire and is covered with a high-temperature resistant silicone rubber insulation layer.

5. A high-power charging device according to claim 1, characterized in that, The control motherboard (6) is equipped with a main control chip, a voltage and current sampling circuit and a communication interface module.

6. A high-power charging device according to claim 1, characterized in that, The cooling fan (7) is equipped with a flow guide grille.

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